Remove/install turbocharger - AR09.40-P-6020T

ENGINE 646.951 in MODEL 211.004 

ENGINE 646.961 in MODEL 211.006 /206 /606 

ENGINE 647.961 in MODEL 211.016 /216 /616 

ENGINE 648.961 in MODEL 211.023 /223 /026 /226 

Fig 1: Identifying Turbocharger Components - Shown On Engine 646.961

Shown on engine 646.961 

	Remove/install
	Risk of death  caused by vehicle slipping or toppling off of the lifting platform.	Align vehicle between the columns of the and position the four support plates below the lifting platform support points specified by the vehicle manufacturer.	AS00.00-Z-0010-01A
	Risk of accident  caused by vehicle starting off by itself when engine is running. Risk of injury  caused by contusions and burns during starting procedure or when working near engine	Secure vehicle to prevent it from moving. Wear closed and snug-fitting work clothes. Do not grasp hot or rotating parts.	AS00.00-Z-0005-01A
	Notes on self-locking nuts and bolts		AH00.00-N-0001-01A
1	Remove bottom section of sound-proofing capsule		AR94.30-P-5300T
2	Remove air filter housing		AR09.10-P-1150T
3	Remove heat shield above turbocharger (3)		AR49.00-P-1000-01T
4.1	Loosen primary catalytic converter	Engine 646.951 in model 211.004 except particulate filter code 474 Engine 646.961 in model 211.006/206/606 except particulate filter code 474 Engine 647.961 in model 211.016/216/616 Near-engine mounted on the turbocharger (3) and bracket on the crankcase.	AR49.10-P-5510T
4.2	Loosen catalytic converter	Engine 646.951 in model 211.004 with particulate filter code 474 Engine 646.961 in model 211.006/206/606 with particulate filter code 474 Engine 648.961 in model 211.026/226 except particulate filter, code 474	AR49.10-P-5500TS
		On the turbocharger (3) and bracket on the crankcase.	AR49.10-P-5500TA
4.3	Loosen catalytic converter-diesel particulate filter device	Engine 648.961 in model 211.026/226 with particulate filter, code 474 Engine 648.961 in model 211.023/223 On the turbocharger (3) and bracket on the crankcase.	AR49.10-P-5501TA
5	Remove air intake hose (1)	Installation:  the air intake hose (1) must not be installed along with the sealing ring, otherwise the sealing ring will be crushed. Parts of the crushed sealing ring may then damage the turbocharger (3). Installation:  first fit the sealing ring for the air intake hose (1) on the turbocharger (3). Check condition of air intake hose (1) and hose clamp.
	Notes on installing the air intake hose on the turbocharger		AH09.40-P-0001-02OM
6.1	Remove charge air pipe (2)	Engine 951/961646, 647.961	AR09.41-P-1311T
6.2	Detach engine charge air duct from exhaust turbocharger (3)	Engine 648.961	AR09.41-P-8623T
7.1	Disconnect turbocharger (3) from alternator	Engine 646, 647 To do this, unscrew bolts (4).
	Bolt on support brace between turbocharger and alternator altered	Engine 646	BT09.40-P-0003-01A
		Bolt of alternator to timing case cover	*BA15.40-P-1001-01D
		Bolt for turbocharger support on alternator	*BA09.40-P-1009-01E
		Torque wrench	Fig 2
		Plug in TORX box wrench	*WH58.30-Z-1065-06A
8	Remove oil feed line (5)	Installation:  Replace sealing rings, in order to preclude leakage. At cylinder head and turbocharger (3) by removing bolts (6, 7).
		Bolt of oil feed line to turbocharger	*BA09.40-P-1003-01E
		Bolt of oil feed line to cylinder head	*BA09.40-P-1004-01E
9	Remove support brace (9) on underside of the turbocharger (3)	Unscrew bolt (10). Installation:  to install the exhaust gas turbocharger (3) without tension, loosen the support bolt (9) on the crankcase
		Bolt of support to turbocharger	*BA09.40-P-1005-01E
		Bolt of turbocharger support to crankcase	*BA09.40-P-1006-01E
10	Unplug connector (11) from turbocharger (3)
11	Dismount the turbocharger (3) from the exhaust manifold	Unscrew bolts (12).
		Flange connection of exhaust manifold to turbocharger	*BA09.40-P-1001-01E
12	Lift turbocharger (3) up and out	The oil drain line (8) must be taken out upwards simultaneously. Collect oil which flows out in a suitable vessel.
13.1	Dismount oil drain line (8) from turbocharger (3)	Only if turbocharger (3) is replaced.
		Bolt of oil drain line to turbocharger	*BA09.40-P-1002-01E
14.1	Remove heat shield on turbocharger (3) and machine	Model 211.016/216/616 up to 01.03.04 with engine 647.961, when installing new turbocharger Remove heat shield from side of turbocharger (3)	AR09.40-P-6020-12T
15	Install in the reverse order
	Check
16	Check engine oil level	Engine 646 in model 211 with Lanchester	AR18.00-P-3035-01T
		Engine 646 in model 211 without Lanchester	AR18.00-P-3035-01Q
		Engine 647 in model 211	AR18.00-P-3035-01S
		Engine 648 in model 211	AR18.00-P-3035-01BD
17	Inspect engine for leaks	With engine running.
18	Read out fault memory and erase	Stored faults which may be caused by removal, test work, removed lines or a simulation, must be processed and erased in the fault memories after completing the work.
	Connect STAR DIAGNOSIS and read out fault memory		AD00.00-P-2000-04A
		STAR DIAGNOSIS diagnosis system	*WH58.30-Z-1048-13A

TURBOCHARGER

ALTERNATOR

Fig 2: Identifying Torque Wrench (001 589 86 21 00)